Fatigue

MSE527
 Fatigue
• Fatigue is the name given to failure in response to
alternating loads (as opposed to monotonic
straining).
• Instead of measuring the resistance to fatigue
failure through an upper limit to strain (as in
ductility), the typical measure of fatigue resistance
is expressed in terms of numbers of cycles to
failure. For a given number of cycles (required in
an application), sometimes the stress (that can be
safely endured by the material) is specified.
 S-N Curves
• S-N [stress-number of cycles to failure] curve defines locus of
cycles-to-failure for given cyclic stress.
• Rotating-beam fatigue test is standard; also alternating tension-
compression.
• Plot stress versus the [Hertzberg]
log(number of cycles
to failure), log(Nf).

• For frequencies < 200Hz,

metals are insensitive to
frequency; fatigue life in
polymers is frequency
dependent.
• High Temp Behavior of Materials:
Mechanical degradation
Chemical Degradation

• Gas Turbine and jet Turbine

• Nuclear reactors
• Power plants
• Spacecraft
• Chemical processing
• Homologous temperature:
• Th = (tcreep+273)/(tmelting +273)
• Th > 0.5 Creep is a concern

• Creep test: measure dimensional changes

Focuses on early deformation stages
Creep conducts: Const Load Engineering purpose

Stress Rupture test: effects of Temp on long time

load bearing characteristics, r.
• Creep is the tendency of a solid material to slowly
deform permanently under the influence of stresses. It
occurs as a result of long term exposure to levels of
stress that are below the yield strength of the material.
Creep is more severe in materials that are subjected to
heat for long periods, and near the melting point. Creep
always increases with temperature.

• The rate of this deformation is a function of the material

properties, exposure time, exposure temperature and the
applied structural load. Depending on the magnitude of
the applied stress and its duration, the deformation may
become so large that a component can no longer
perform its function — for example creep of a turbine
blade will cause the blade to contact the casing, resulting
in the failure of the blade.
• Creep is usually of concern to engineers and
metallurgists when evaluating components that
operate under high stresses or high
temperatures.

• Creep is a deformation mechanism that may or

may not constitute a failure mode. Moderate
creep in concrete is sometimes welcomed
because it relieves tensile stresses that might
otherwise lead to cracking.
Test Coupon
 Material Properties

STRENGTH - the greatest stress that the material can

withstand prior to failure.
DUCTILITY - a material property that allows it to undergo
considerable plastic deformation under a load before
failure.
ELASTICITY - a material property that allows it to retain its
original dimensions after removal of a deforming load.
STIFFNESS - a material property that allows a material to
withstand high stress without great strain.
 The Tensile Tester

A machine which applies a tensile force (a

force applied in opposite directions) to the
specimen, and then measures that force
and also the elongation:
This machine usually uses a hydraulic
cylinder to create the force. The applied
force is determined by system pressure,
which can be accurately measured.
Tensile Tester Data Acquisition Unit
Stress - Strain Curve
THE SAMPLE

Area of measured test

Marking the sample:
A precision punch with
two points exactly
2.000” apart is used to
mark the sample in the
tested region.

This establishes the

original length.
This device, called an
EXTENSOMETER,
measures the distance
between the two prongs
very precisely while the
test is in progress.
Before After
A Stainless Steel
sample is loaded in
the tester.
 Terms

Necking: The localized decrease in diameter in a

specimen near the rupture point.

Elastic Deformation Region: The area of a stress -

strain curve where the specimen will deform under load, yet
return to its original shape when the load is removed.

Plastic Deformation: Deformation that occurs once

the object has been stressed past its elastic limit. The
deformation is no longer reversible.
 Necking

“Necking” occurs as
the sample leaves
the elastic
deformation region
and begins to
deform plastically.
The classic cup &
cone shape of a
fairly ductile tensile
fracture is visible
here.
Upon completion of the test, the sample is
reassembled and final measurements for total
elongation and minimum diameter are made
using a vernier caliper.
For maximum precision, the points of the vernier
caliper must be placed exactly at the center of the
marks made by the punch prior to the test.
Compare the material properties of
these three metal samples.

All three failed under tension

 PLASTIC DEFORMATION REGION

ELASTIC DEFORMATION REGION

 Why Perform a Flexure Test?
A flexure test produces tensile stress in the convex side of the
specimen and compression stress in the concave side. This creates
an area of shear stress along the midline. To ensure the primary
failure comes from tensile or compression stress the shear stress must
be minimized. This is done by controlling the span to depth ratio; the
length of the outer span divided by the height (depth) of the specimen.

For most materials S/d=16 is acceptable.

Some materials require S/d=32 to 64 to
keep the shear stress low enough.
The Flexural test measures the force required to bend a
beam under 3-point loading conditions.

The data is often used to select materials for parts that will
support loads without flexing.

Flexural modulus is used as an indication of a material’s

stiffness when flexed.
 3-Point Bend test
In this test a specimen with rectangular or flat cross-section is placed on two
parallel supporting pins. The loading force is applied in the middle by means
loading pin.
The supporting and loading pins are mounted in a way, allowing their free
rotation about:
-axis parallel to the pin axis;
-axis parallel to the specimen axis.
For a rectangular cross section,
Testing method
Calculation of the flexural stress ,

Calculation of the flexural strain ,

Calculation of flexural modulus ,

Compression Test
Hardness Test
Torsion Test
Impact Test
Fracture Toughness Test
NDT- Ultrasonic